Assembly of XFEL Cryomodules: Lessons and Results · 2017. 6. 6. · • AMTF averagegradient is18% abovespecs: ¢Eacc²= 27.8 MV/m. • All but 7 of 103 testedmodules are on XFEL

XFELX-Ray Free-Elect ron Laser

Assembly of XFEL Cryomodules: Lessons and Results

1

S. Berry, CEA-Saclay, Irfu/SACM

2016 September 28th LINAC16, MSU

XFELX-Ray Free-Elect ron LaserOutline

Cryomodule production• Delivery and throughput• Quality control

Module performance vs. Clean Room proceduresModule repair activitiesConclusions


XFELX-Ray Free-Elect ron LaserE-XFEL Cold Linac 17.5 GeV

1 + 100 accelerator modules

808 accelerating cavities1.3 GHz / 23.6 MV/m / 1010

25 RF stations 5.2 MW each



CEA deliverable to European XFEL:

assembly of 103 accelerator modules

on the Saclay site and with CEA* infrastructure* nine pumping systems (with mass-spectrometer) and one laser-tracker from DESY

* two tuner control racks from INFN

Workforce by an industrial contractor Alsyom:

Quantity production goal: 1 module / week

Quality performance goal: Eacc > 23,6 MV/m

Cryomodule Production



the XFEL Village

Module integration route

Coupler Area CO-WS1

Alignment Area AL-WS1 & 2

Shipment Area

SH-WS1 & CO-WS2

Roll-out Area

RO-WS1 & 2Warehouse

Clean room Area

CC-WS1 & 2SA-WS1 & 2

Cantilever Area CA-WS1

Assembly Hall : Workstations


XFELX-Ray Free-Elect ron LaserComponent Industrialization / Handover

Cryo-systems

Vacuum vessels

45 from Zanon, 58 from IHEP/DESY

Tuners / DESY

800 Cavities / DESY400 Zanon / 400 RI

Helium tanks / DESY600 Zanon / 200 CNC / DESY

Current leads / DESY

Couplers / IN2P3650 Thales-RI150 CPI

Quadrupole-BPM / DESY103 Magnets / CiematBPM / 72 DESY – 31 CEA206 Gate Valves / DESY

Magnetic Shields / CEA

Bellows / BINP

6

There are 9 422 individual components integrated

and over 12 400 individual parts manipulated

per cryomodule


XFELX-Ray Free-Elect ron LaserCryomodule Delivery

7

2016:25 modules

Figure: delivery of cryomodules, from XM-3 to XM100

• 103 modules delivered to DESY (incling XM-3, XM-2, XM-1).

• In 2015, one cryomodule was delivered every 4 days, 52 in total.

• The Cold Linac includes also two pre-series cryomodules: XM-2 and XM-1

• The shipment of XM100 was on 27 July 2016

2015:52 modules

2014:24 modules

XM-3 XM-2



54

XM 4

L2L1

8

XM 5 XM 1 XM 2 XM -1

L3

L3

L3

L3

L3

Installation Progress XTL

Status: 16.09.2016

L001A2.1.L1 BC1

L2

L3

L3

BC2

XM 7 XM 6 XM11 XM 3 XM 13 XM 9 XM 10 XM 19

L002A2.2.L1

L003A2.3.L1

L004A2.4.L1

L005A3.1.L2

L006A3.2.L2

L007A3.3.L2

L008A3.4.L2

L009A4.1.L2

L010A4.2.L2

L011A4.3.L2

L012A4.4.L2

L013A5.1.L2

L014A5.2.L2

L015A5.3.L2

L016A5.4.L2

L017A6.1.L3

L018A6.2.L3

L019A6.3.L3

L020A6.4.L3

L021A7.1.L3

L022A7.2.L3

L023A7.3.L3

L024A7.4.L3

L025A8.1.L3

L026A8.2.L3

L027A8.3.L3

L028A8.4.L3

L029A9.1.L3

L030A9.2.L3

L031A9.3.L3

L032A9.4.L3

L033A10.1.L3

L034A10.2.L3

L035A10.3.L3

L036A10.4.L

3

L037A11.1.L3

L039A11.3.L3

L040A11.4.L

3

L041A12.1.L3

L042A12.2.L3

L043A12.3.L3

L044A12.4.L3

L045A13.1.L3

L046A13.2.L3

L047A13.3.L3

L048A13.4.L

3

L049A14.1.L3

L050A14.2.L3

L051A14.3.L3

L052A14.4.L

3

L053A15.1.L3

L054A15.2.L3

L055A15.3.L3

L056A15.4.L3

L057A16.1.L3

L058A16.2.L3

L059A16.3.L3

L060A16.4.L

3

L061A17.1.L3

L062A17.2.L3

L063A17.3.L3

L064A17.4.L

3

L065A18.1.L3

L066A18.2.L3

L067A18.3.L3

L068A18.4.L

3

L069A19.1.L3

L070A19.2.L3

L071A19.3.L3

L072A19.4.L

3

L077A21.1.L3

L078A21.2.L3

L079A21.3.L3

L080A21.4.L

3

L089A24.1.L3

L090A24.2.L3

L091A24.3.L3

L092A24.4.L

3

L081A22.1.L3

L082A22.2.L3

L083A22.3.L3

L084A22.4.L

3

L093A25.1.L3

L094A25.2.L3

L095A25.3.L3

L096A25.4.L

3

L073A20.1.L3

L074A20.2.L3

L075A20.3.L3

L076A20.4.L

3

L085A23.1.L3

L086A23.2.L3

L087A23.3.L3

L088A23.4.L

3

L097A26.1.L3

L098A26.2.L3

L099A26.3.L3

L100A26.4.L

3

L038A11.2.L3

XM 18

DEMACO Cryo-connection

1.508 m

XM 27 XM 20

A2

A6

XM 30A7 A8

XM 31 XM 28 XM 14XM 34

P

XM 26 XM 35XM 37

SCB 1

DEMACO Cryo-connection

XM 38 SCB 2XM 39 XM 40 XM 41 XM 36

XM 43 XM42

96 Modules installed 1 RF-Station ready23 RF-Station in preperation

XM47XM44

P P

XM 49XM 16 XM 33XM 45XM 15

A9 A10

52 53 55 56 57 58 59 6160 62 63

XM 51XM 17

XM55

XM 52XM 53XM 25

A11

A12 A13 A14

XM 32

XM 67

P

XM 56

P

P

XM 48XM 23 XM 58

XM59

XM 12

P

P P

SCB 4

XM65

6867 70 747372 75696664 76

XM 64 XM 60

SCB 3

XM 57

XM 71

UV XTL-2AV

XM 63 XM 66

51

XM 21

XM 61

XM 69XM 68 XM 70

A5

A15 A16 A17

XM 72XM 73

XM 76XM 62

A4

A3

P

PP P

CS1 CS2

CS2

CS3

CS4

CS5

CS6

CS7

CS8

CS9

65

32

797877 80 81 82 83 84 85 86 87 88 89

XM -2XM 74XM 77 SCB 5XM 79

P PP

XM 81XM 80XM 78 XM 75

90 91 93 94 100

BC0DoglegInjectorDEMACO Cryo-connection

95 96 97 98 99 102101

P

SCB 6

P

XM83 XM82XM 22 XM84XM 86XM87XM 85

<<< Cabling >>>

22 24 25 26 28

P29 30 31 33 34 35 36 37

71

92

A18 xx xA19 A20

XM 89XM 88XM 90XM 92XM 54

<<< Rack cabling >>>

P P P

x x xA22 A23

103

XM 95XM 94XM 93

104 105 106 107 108 109 110 111 112 113 114

118

XM 91 XM 24XM 97XM 96 LastXM98

P P PA21

A24

23

116 120 126

x x A25

<< cabling >>

Wave Guide assembling

117 119 121 122 123 125 127



Interlock-door 1.102m

115

124 128

parked

End cap

129

133 137

Mobil Cleaning Room

Mobil Cleaning Room


<< Cleaning CS7 Racks + Floor >>


Connecting Power cable to Station


XFELX-Ray Free-Elect ron Laser2016-08-18


XFELX-Ray Free-Elect ron LaserProduction Throughput

10

• 5 days throughput was reached mid-October 2014 with XM15the design of the Assembly Infrastructure was sound

• 4-day throughput was reached in January 2015 with XM25

Courtesy

July 2016: XM100

March 2014: XM1


XFELX-Ray Free-Elect ron LaserImproving Integration Processes

11

Acceleration and Quality of Production benefited mostly from:• New clean room assembly procedure: moving individual cavity venting

after the leak check of the cold coupler assembly, rather than later, before the string assembly. This eliminates one connection to pumping stations for cavity venting, and one valve closing-opening cycle.

• New equipment, e.g. string leak test plexi-box:

• Pure Argon gas for Titanium welding, instead of He-Ar (50%-50%),to avoid the long and unpredictable time to pump and purge the LHetank to reach the He background for the leak test (LT) by externalaccumulation.

• Reducing the impact of non-conformities, particularly imported NC.More human resources have been put on incoming inspection and QC.


XFELX-Ray Free-Elect ron LaserQuality Control: Non Conformities

Non Conformities recorded by Alsyom fall into 3 categories:1) Tooling and equipment (TOOLING), responsibility by CEA/DESY2) Accelerator components (PRODUCT), responsiblity by suppliers3) Assembly operations (PROCESS), responsibility Alsyom

The number of PRODUCT Non-Conformities has not gone down. But, with better and more efficient detection at incoming inspection, the impact of PRODUCT NC on the module assembly has considerablydecreased, compared to when many NC were discovered ‘on the fly’.


XFELX-Ray Free-Elect ron LaserQuality Control

13

Ask for torque specification from the begining

Alsyom QC ,

CEA QC ,The Quality Control

of QC is needed !


XFELX-Ray Free-Elect ron LaserCryomodule Performance at AMTF

• AMTF average gradient is 18% above specs : Eacc = 27.8 MV/m.• All but 7 of 103 tested modules are on XFEL specs (23.6 MV/m):

• XM33, XM58 XM68 XM98 and XM99 are limited by individual cavityperformance

• XM45 was impacted by a clean room power outage• XM46 was impacted by beam vacuum leaks

14

Average operating gradient per cryomodule, clipping the VT results to 31 MV/m

111315171921232527293133

XM-3

XM-1

XM2

XM4

XM6

XM8

XM10

XM12

XM14

XM16

XM18

XM20

XM22

XM24

XM27

XM29

XM31

XM33

XM35

XM36

XM38

XM40

XM42

XM44

XM46

XM48

XM50

XM52

XM54

XM56

XM58

XM60

XM62

XM64

XM66

XM68

XM70

XM72

XM74

XM76

XM78

XM80

XM82

XM84

XM86

XM88

XM90

XM92

XM94

XM96

XM98

XM10

0

Average RF gradient (MV/m) for taylored RF distribution/individual cavities

spec

Eacc VT

Eacc AMTF


XFELX-Ray Free-Elect ron LaserXM71 Performance

Cavities 2,4, 6 and 8 have higher field emissionin VT (@quench limit gradient) than in AMTF (@ 31 MV/m power limit).

15

Cavity field emissionQuench Limit

Operating Gradient

MT @ 31 MV/m

VT @ 34-38 MV/m


XFELX-Ray Free-Elect ron LaserCryomodule Performance : XM46

16

XM46 string was leaky in the clean room AND before shipment. Bothleaks have been repaired at Saclay but they generated 2 extra connections of the beam vacuum to pumping groups, and 2 additional venting-pumping

Eacc = 19,7 MV/m


XFELX-Ray Free-Elect ron LaserAbout Gradient Comparison

• Accelerating gradients are the most scrutinized module performance parameters, although heat loads, alignment and PED certification are entering the acceptance criteria.

• The absolute gradient is the result of the whole production chain, from the Nb sheet to the module test (MT). It is mostly determined bycavity manufacturing and module assembly.

• The quality of module assembly shows in the gradient differencebetween cavity acceptance (VT) and module acceptance (MT).

• The VT vs. MT comparison of both the ‘maximum’ and the ‘operational’ gradients is impaired by a systematic error:

1. Maximum gradients depend on 1) RF duty cycle, 2) cooling conditions and, 3) magnetic environment, which are completely different from VT to MT

mostly cavity-independent error2. Operational gradients depend, in addition, on X-Ray measurement

devices which are different from VT to MT (although cross-calibrated)mostly cavity-independent error

3. Finally, Q0 is not measured in MT: therefore the MT usable gradient couldcorrespond to lower or higher Q0 values cavity-dependent error


XFELX-Ray Free-Elect ron LaserCryomodule Performance: VT vs. MT

• Significant gradient degradation from XM6 to XM23, while CEA and Alsyom put all their effort in achieving production goal of 1 CM/week: an audit of string and module assembly wasconducted by CEA on XM26

• A simplification of the clean room procedures was introduced at XM54: no degradation after

18

1st sample of 34 series CMEop = -2.1 MV/m

2nd sample of 19 series CMEop = -1.7 (-0.9) MV/m

last 48 series CMEop =+0.4 MV/m

CEA AuditNew clean

room procedure


XFELX-Ray Free-Elect ron LaserXM26 Clean Room Assembly Audit

Audit Findings:• Operators walk too fast in the clean room.• Record the cleanliness level (< 10 particles / min) reached on the

angle valve before the pump connections to the cavity (CC and SA).• Two operators are requested to connect cavity to the pumping

system (CC and SA).• Two operators are requested to position inter-cavity bellows and

screw first 4 studs (SA).• Careful pre-alignment of parts (coupler and cavity flanges at CC,

inter-cavity bellow/cavity-coupler-side flange at SA) is requested for easy and clean assembly.

• Improvement of operator positions versus critical RF surfaces (avoid top assembly, request seated).

• Gate valve connection to pumping system procedure has been reviewed to ensure better cleanliness (CC).


XFELX-Ray Free-Elect ron LaserSA-WS: pre-alignement of bellows

Observation during XM26 assembly


XFELX-Ray Free-Elect ron LaserClean Procedures: Comparison

21

Procedure n°1 n°2 n°3 n°4

# Gate valve to pipe connections 34 22 14 14

# Gate valve open/close cycles 33 21 13 13

# N2 blowing after an opening 17 17 9 9

# Leak checks 52 40 32 23

Number of vacuum operations for a complete cryomodule assembly


XFELX-Ray Free-Elect ron LaserCryomodule Performance: n°1-2 vs. n°3-4

22

Procedures n°3 and n°448 cryomodulesEop = +0.4 MV/m

Procedures n°1 and n°2:54 cryomodulesEop = -2.0 MV/m


XFELX-Ray Free-Elect ron LaserConclusions for Cryomodule Assembly

• E-XFEL Cryomodule Assembly at Saclay implied 4 main overlappingphases:

1. Mastery of assembly procedures [ T1/2008 – T1/2013 ], with XM-32. Mastery of infrastructure and tooling [ T3/2010 – T1/2013 ], at XM-13. Mastery of non-conformities handling, both imported-PRODUCT and

PROCESS-generated non-conformities [ T3/2012 – T3/2014 ], at XM154. ‘Mastery’ of the industrial operator

• Productivity [ T1/2014 – T4/2014 ], at XM25• Quality Assurance [ T4/2014 – ongoing ]

This process depends on the early availability of the cryomodule components: ‘Practice makes perfect’

• The difficulties and the risks of coupler assembly had been under-estimated by CEA, especially for the coupler warm part

• Better module RF performance is correlated to Clean Room practice and Clean Room procedures.

• The goal of ‘zero mistake’ has been missed: the rate of ~ 1 major mistake every 2 weeks is an organisational problem.


XFELX-Ray Free-Elect ron LaserConclusions (2/2)

• E-XFEL Cavity production demonstrates the existence of EU vendorsfor cavities in the range 30 – 40 MV/m.

• E-XFEL AMTF demonstrates that RF testing is feasible) at a rate compatible with one ILC hub, even if 100% MT is the chosen option: 11-day cycle per module, with 3 MT bunkers in AMTF

• E-XFEL Cryomodule Assembly demonstrates that a 3-day throughputis feasible for ILC production, leading to about 120 modules per yearon one production site.

• When all assembly equipments are operating under nominal conditions, there are clear indications that RF performance of the cryomodules is impaired by:

• The invasiveness of operators in the clean room• The invasiveness of vacuum operations on the beam vacuum. Both

can be mitigated with good quality control and floor inspections• Clean room assembly can be further improved, qualitatively and

quantitatively, e.g. by unifying cold coupler and string assembly in a unique workstation (2 shifts required to achieve 3-day throughput).



Thanks to my co-workpackage leaders:

WP03 K Jensch and O. Napoly, WP09 A. Matheisen

Thanks to the CEA team:

C. Cloué, C. Madec, S. Régnaud, C. Simon

C. Boulch, P. Charon, J-P. Charrier, M. Fontaine, Y. Gasser, G. Monnereau,

J-L. Perrin, T. Trublet, B. Visentin

Thanks to ALSYOM

P. Pluvy, J. Dumas, C. Abdi, F. Déau, F. Chatillon,

M. Jurado and their team, G. Guillonneau (SEIV)

Thanks to DESY and LAL colleagues

S. Barbanotti, M. Schmöckel, H. Hintz, F. Hoffmann, W. Kaabi, D. Käfer,

R. Klos, L. Lilje, W. Maschmann, M. Schlösser, A. Verguet, and many others

Acknowlegments for Module Integration

25

the last of the cavities



26

Thank you for your attention


Documents

Assembly of XFEL Cryomodules: Lessons and Results · 2017. 6. 6. · • AMTF averagegradient is18% abovespecs: ¢Eacc²= 27.8 MV/m. • All but 7 of 103 testedmodules are on XFEL